Patch and repair kit

ABSTRACT

A kit for repairing an opening, such as a hole or crack, in a wall, ceiling, door, etc. structure, includes a tray having a plurality of receptacles to selectively receive at least a container of patching compound and a container of sprayable material. The kit also includes a planar patch to cover the opening, a resealable container of patching compound, at least one applicator, e.g., for applying the patching compound over the patch, a means for sanding over the patch, and a container, such as a spray can, for storing and applying sprayable material over the patch. The kit may also include a replaceable lid, and the tray may include one or more additional receptacles to selectively receive the sanding means and/or the applicator(s).

RELATED APPLICATION DATA

This is a continuation-in-part of application Ser. No. 11/042,570, filed Jan. 25, 2005, the entire contents of which are incorporated herein by reference.

FIELD OF INVENTION

This invention relates generally to systems for repairing holes or cracks in walls, ceilings, doors, and similar structures and, more specifically, to a unitary kit for repairing such openings with sprayable composition materials.

BACKGROUND OF THE INVENTION

Wall and ceiling surfaces have traditionally been susceptible to cracks and holes that may appear for a multitude of reasons. In cases where the opening is small, such as holes that are caused by nails for hanging picture frames or by screws for hanging curtain rods, the opening may be patched by spackle or other similar material generally known in the art.

For larger openings, the art has suggested the use of various mechanical devices, wherein the latter are used to essentially “plug” the hole. Once the opening is closed off, whether by mechanical or other means, a patching compound must generally be applied to the damaged surface to prepare the latter for painting, such that the previously-damaged surface of the structure is brought into conformity with the remainder of the surface surrounding the opening. Such patching compounds are also known in the art.

The above-mentioned devices and means, including the tools necessary for installation and/or application thereof, are generally packaged and sold separately. Thus, in order to repair a hole in a wall, for example, the consumer must locate and purchase at least the following components separately: a patch or patching device; a patching compound; one or more applicators (e.g., a putty knife or trowel), depending on the size and shape of the hole, for applying the patching compound; and sand paper, or other means for sanding the patched surface. In addition, once all of the above-noted components have been obtained, the consumer must also keep them all together in one place, so as to avoid misplacing any one of them for a subsequent repair job.

In short, the process of obtaining all of the necessary repair components, is generally inefficient, costly, and time-consuming and, once the various components have been obtained, there are no provisions for keeping the components together in an orderly fashion either during or after use. A need, therefore, exists for a repair kit that includes not only all of components that may be required in repairing an opening in a structure, but also a customized tray to hold the various components in a logical, easily-accessible manner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tray in accordance with an embodiment of the present invention;

FIG. 2 is a perspective view of a spray can of composition material in accordance with an embodiment of the present invention;

FIG. 3 is a perspective view of a container of patching compound in accordance with an embodiment of the present invention;

FIG. 4 is a top view of a planar patch in accordance with an embodiment of the present invention;

FIG. 5 is a perspective view of a sanding block in accordance with an embodiment of the present invention;

FIG. 6 is a plan view of a narrow putty knife in accordance with an embodiment of the present invention; and

FIG. 7 is a plan view of a wide putty knife in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

FIG. 1 shows an empty tray 5 having a plurality of receptacles 10,20,30,40,50. Each of the receptacles 10,20,30,40,50 is shaped so as to selectively receive a different component of a patch and repair kit for repairing an opening (e.g., a hole, crack, etc.) in a wall, ceiling, door, or other structure according to the present invention.

As shown in FIGS. 2-7, in a preferred embodiment, the components of the kit include a spray-type can 110, a sanding block 120, a jar-type container 130, a narrow putty knife or trowel 140, a wide putty knife or trowel 150, and a planar patch 160. Spray can 110 contains sprayable material that may be applied through an adjustable spray nozzle 112. The sprayable material, in turn, may be “knockdown” spray texture, “orangepeel” spray texture, acoustic spray texture, stucco spray texture, sand-finish spray texture, or other spray texture that may be used to treat ceilings, interior walls, exterior walls, etc. Alternatively, the sprayable material may be a smooth composition, such as, e.g., primer material, that may be used to treat ceilings, interior walls, exterior walls, etc. Spray can 112 may be of the type that is available, e.g., through Spraytex, Inc., located in Valencia, Calif.

The jar 130 contains a wall patching compound, or joint compound, and is also available through Spraytex, Inc. Another component that is sold through Spraytex, Inc. is the planar patch 160. As shown in FIG. 4, the planar patch 160 has a perforated, flexible plate 164 that is sandwiched between a removable backing material 162 and a mesh 166. Preferably, the patch 160 is self-adhesive, such that, when the backing material 162 is removed, the plate 164 and mesh 166 will stick to a surface to which the patch is applied.

FIG. 5 shows a sanding block 120 which is generally known in the art. In a preferred embodiment, four of the six sides of the sanding block 120, i.e., faces 122 and 124, as well as the two faces opposite thereto (not shown), have rough surfaces suitable for sanding applications. Lastly, FIG. 6 shows a narrow putty knife, or trowel, and FIG. 7 shows a wide putty knife, or trowel, of the type known in the art.

With reference to FIG. 1, tray 5 is configured such that spray can 110 fits into, and is selectively received in, receptacle 10; sanding block 120 fits into, and is selectively received in, receptacle 20; container 130 fits into, and is selectively received in, receptacle 30; the top (i.e., straight) portion 142 of trowel 140 fits into, and is selectively received in, receptacle 40, with the trowel's handle resting on top of the sanding block 120; and the top portion 152 of the wide trowel 150 fits into, and is selectively received in, receptacle 50, such that the top portion 152 thereof rests partially on the top portion 142 of narrow trowel 140, and the handle of the wide trowel 150 is situated above the sanding block 120.

In practice, the repair kit of the instant invention is packaged to have the arrangement described immediately above. With this arrangement, the planar patch 160 is then placed on the very top, such that it rests, e.g., on the wide trowel 150, followed by a removable lid, or cover, that is placed on top of the planar patch 160. Both the lid and the tray 5 also have matching slots 7 that allow the entire kit, or package, to be hung vertically from a cantilevered hanger (or other point-of-sale mechanism) at retail stores. The package may also be placed vertically or horizontally on a store shelf.

When a consumer wishes to repair an opening in a wall (or ceiling, etc.), the consumer need only purchase the above-described package containing the tray and components therein. In this way, there is no need to look for and purchase the necessary components separately. In addition, the tray provides a well-organized working aide during treatment of the repair site, as well as an organized, unitary storage compartment subsequent to such treatment.

In particular, treatment, or repair, of an opening in a wall (or ceiling, etc.) may be effected in the following manner. The cover is taken off the package containing the tray, and the components are removed. The backing 162 is peeled off and the self-adhesive patch 160 is placed over the opening (the patch may be cut to size as necessary). A trowel 140,150 is then used to apply patching compound from the container 130 over the patch 160, and the site is left to dry. Next, the sanding block 120 is used to smooth the surface, followed by application of composition material from the spray can 110.

As mentioned, the spray can 110 may have an adjustable nozzle 112 which allows matching of the texture of the treated area to that of the surrounding area. Thus, when, for example, a repair kit having a knockdown-texture spray can is purchased, and the surrounding area is of the heavy splatter type, then, upon application of the texture material, the treated area may just be left to dry, followed by priming and painting, as desired. In this case, the kit may include only a narrow trowel 140 (and only one corresponding trowel receptacle 40). On the other hand, when a knockdown or “lace” finish is desired, the wide putty knife 150 may be dampened with water and run gently over the treated area at an approximately 45° angle. Once finished, the treated area is allowed to dry, and then primed and painted as desired.

In an alternative embodiment, the composition contained within the spray can 110 may be a smooth priming material for use with surfaces that are not textured. Thus, once the surface to be treated has been sanded, the smooth composition (e.g., primer) material is sprayed onto the surface. The smooth composition material is then allowed to dry and the surface is painted, thereby creating a smooth, rather than a textured, overall surface.

Upon completion of the repair job, the container 130 is then resealed and it, along with the rest of the components of the repair kit, are placed in their respective receptacles in tray 5 for easy and readily-accessible storage. The lid may also be replaced prior to stowing the kit away, which may be done by placing the kit flat on a shelf, cabinet, etc., or by hanging the kit from a hook or other retaining means (such as, e.g., from a wall in a garage).

While the description above refers to particular embodiments of the present invention, it will be understood that modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.

The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. 

1. A repair kit system for repairing an opening in a wall or ceiling structure, comprising: a tray having a plurality of receptacles arranged in a predetermined configuration with respect to one another, said plurality of receptacles including at least a first receptacle shaped to selectively receive a container of patching compound, a second receptacle shaped to selectively receive a container of sprayable material, a third receptacle shaped to selectively receive an applicator, and a fourth receptacle shaped to selectively receive a sanding means; a resealable container of patching compound; a container having sprayable material therein; a first applicator for applying said patching compound; a sanding means; and a planar patch.
 2. The repair kit system of claim 1, further including a second applicator.
 3. The repair kit system of claim 2, wherein the first applicator has a narrow blade, the second applicator has a wide blade, and the tray further includes a fifth receptacle shaped to selectively receive the second applicator.
 4. The repair kit system of claim 1, wherein said sanding means is a sanding block.
 5. The repair kit system of claim 1, wherein said sprayable-material container is a spray can.
 6. The repair kit system of claim 1, wherein said sprayable material is a smooth composition material.
 7. The repair kit system of claim 6, wherein said smooth composition material is a primer.
 8. The repair kit system of claim 1, wherein said first applicator is a putty knife.
 9. The repair kit system of claim 1, wherein said patch is self-adhesive.
 10. The repair kit system of claim 1, wherein said tray has a replaceable lid. 